Strata EZITIG 180 Operating Instructions Manual

Brand: Strata

Model: EZITIG 180

Category: Welding System

Type: Operating Instructions Manual

EZITIG 18 0

OPERATING INSTRUCTIONS

MULTI-PROCESS TIG WELDER

CONSTANT

CURRENT

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2www.strata.co.nz

EZITIG 180

Congratulations on your new Strata product!

The Strata range from Euroquip uses latest technology design and engineering to produce

welding products that combine market leading value and features with durability. Designed

for discerning operators who seek professional results and product quality without the price

tag of a full professional setup. Design emphasis is placed on simple, functional design

and operation. Strata product is subject to stringent quality control and designed and

manufactured to NZ & Australian standards.

Common use of Strata products include:

 • LightEngineering

 • Automotive

 • Home/HobbyEngineering

 • Farming

 • IndustrialMaintenance&Repairs

Forindustrialweldingsolutions,checkouttheStratarangefromEuroquip:

www.strata.co.nz

Euroquip is a market leading provider of innovative power equipment solutions to a wide

range of industries across New Zealand and Australia. Key product categories are; welding

equipment, air compressors, power generators and cleaning equipment.

Euroquip’s slogan is ‘empowering industries’, find out more about the advantage Euroquip

brings at www.euroquip.co.nz.

Providing exceptional product support is a key component of Euroquip’s market leading

customer advantage focus. As part of this program, it is required for all products to be

registered with Euroquip to qualify for product support. Products not registered with Euroquip

are supported by a base 12 month warranty only. Spare parts and technical support will not

beavailableforanunregisteredproductoutsideofthisbasewarrantyperiod.IfaEuroquip

dealer has not already registered your product, please register it online at www.euroquip.

co.nz. To request a physical registration form, please download one at www.euroquip.co.nz

under the ‘Contact Us’ tab.

www.strata.co.nz

EZITIG 180

Contents

KnowYourMachine............................................................5

Quick Start Guide................................................................6

Available Parts & Accessories..............................................7

3PinRemotePlugConnection...........................................8

Wiring Diagram...................................................................9

Care&Maintenance..........................................................10

Electrodes.........................................................................10

EffectsofMMAWeldingVariousMetals...........................11

BasicMMAWeldingGuide..............................................12

MMAWeldingTechniques.................................................13

OtherKnowledge&Resources.........................................16

MMATroubleshooting......................................................17

TIGWeldingGuide............................................................18

TIGTroubleshooting.........................................................20

Safety..............................................................................21

Warranty.........................................................................27

4www.strata.co.nz

EZITIG 180

• EZITIG 180 •

MULTI-PROCESS TIG WELDER

The EZITIG 180 is a powerful, extremely portable and easy to use TIG & MMA (Stick) unit. Extreme

stress tested to 440V from the factory with IP23 moisture and salt spray protection, the EZITIG

180 has protection against the most harshest environments. Featuring the HF Start and 180A DC

current, it is ideal for mild and stainless steel work such as wine vats, maintenance roll cages

and industrial TIG work.

• IGBTInvertertechnologyforsmooth&stable 

welding output and increased reliability

• Microprocessorcontrolsystemforsuperior& 

dynamic arc characteristics

• Lightweight&compactdesign,idealforportable

applications

• Extremestresstestedinproductionupto440Vfor

rugged reliability

• Strongenvironmentalprotectionforprotection

againt moisture, salt spray and corrosion

• Automaticarcforce,hotstart&antistickcontrolfor

 greatercontrolandeaseofusewhenMMAwelding

• HFTIGarcignitionsystemforcontaminationfree

and easy arc starting

• 2T/4ttriggercontrol

• Digitaldisplaymeterforaccuratesetting&

feedback of welding output

• Highquality&overspecifiedelectroniccomponents

for durability & reliability

• Quickconnectinletgasfittingforeaseofuseand

changing bottles between machines.

DIMENSIONS: WEIGHT: INPUT POWER MAX. INPUT GENERATOR CURRENT MMA O/C DUTY CYCLE: STANDARDS: MAX WELD

SUPPLY: CURRENT: CAPACITY: OUTPUT: VOLTAGE: THICKNESS:

410x146x278mm 5.5kg 230VAC15A 40A 9.8KVA 10-180A 74V 60%@125A EN60974-1:2012 8mm

50Hz       

CONSTANT

CURRENT

www.strata.co.nz

EZITIG 180

*Denotes more detailed explanation of function to follow.

1. Digital current display meter

2. Welding output mode switch. Sets power

 sourceinTIG2T,TIG4TorMMAmode*

3. TIGpostgasflowcontrolknob*

4. Down slope control knob*

5. Positive (+) welding power output connection socket

6. TIGtorchgasconnector

7. Negative(-)weldingpoweroutputconnection socket

8. TIGtorchremoteconnectionsocket

9. Welding current control knob

10. PowerIndicator.Lightswheninputpower

connected and machine switched on

11. Error/OverloadIndicator*

Further Controls Explained

Overload/ Error Indicator

Lightswhenovervoltage,overcurrentorelectrical

overheating (due to exceeding duty cycle) is detected

and protection is activated. When protection is acti-

vated, welding output will be disabled until the safety

system senses the overload has reduced sufficiently

andindicatorlampgoesout.Mayalsotriggerifma-

chine experiences an internal power circuit failure.

TIG 2T/4T

In2Tmodethetriggerispulledandheldontoacti-

vate the welding circuit, when the trigger is released,

the welding circuit stops. 4T is known as ’latching’

mode. The trigger is pulled once and released to ac-

tivate the welding circuit, pulled and released again

to stops the welding circuit. This function is useful to

longer welds as the trigger is not required to be held

on continuously.

Post Flow

Controls the period of time the shielding gas contin-

ues to flow for after the arc is stopped. This protects

the weld area and torch tungsten from contamination

while it is still hot enough to react with atmospheric

gases, after the weld is finished.

Down Slope

When the trigger is released, the welding current will

reducegraduallyoverthetimeselecteddownto0.

This allows the operator to complete the weld without

leaving a ‘crater’ at the end of the weld pool.

Tips & Tricks

Duty Cycle Rating

Welding duty cycle is the percentage of actual weld-

ing time that can occur in a ten minute cycle. E.g.

20%at160amps-thismeanstheweldercanweldat

160ampsfor2minutesandthentheunitwillneedto

berestedfor8minutes.

All duty cycle ratings are based on an ambient air

temperatureof40°Cwith50%humidity,whichisthe

internationalstandardforsucharating.Inanenvi-

ronmentwithtemperaturesexceeding40°C,theduty

cyclewillbelessthanstated.Inambienttemperature

lessthan40°C,dutycycleperformancewillbehigher.

Know Your Machine 1

6www.strata.co.nz

EZITIG 180

Electrical Connection

TheEZITIG180isdesignedtooperateona15A230V

ACpowersupply.Ifanextensioncordmustbeused,

it should be a heavy duty version with a minimum

cablecoresizeof2.5mm2.Itisrecommendedtouse

theEuroquipindustrialduty15Aextensionlead,part

number;16895.

Operating Environment

Adequate ventilation is required to provide proper

coolingfortheEZITIG180.Ensurethatthemachine

is placed on a stable level surface where clean cool

aircaneasilyflowthroughtheunit.TheEZITIG180

has electrical components and control circuit boards

which may be damaged by excessive dust and dirt, so

a clean operating environment is important for reli-

able product life.

Basic Operation

1. ARC/ MMA Welding Operation

1.1 Connect the earth cable quick connector to the

negative welding power output socket (7) Con-

nect the earth clamp to the work piece. Contact

with the work piece must be firm contact with

clean, bare metal, with no corrosion, paint or

scale at the contact point.

1.2 Insertanelectrodeintotheelectrodeholderand

connect the electrode holder and work lead to

thepositiveweldingpoweroutputsocket(5).

Note: This polarity connection configuration is valid for most

GP(GeneralPurpose) MMAelectrodes.There are variancesto

this.Ifindoubt,checktheelectrodespecificationsorconsultthe

electrode manufacturer.

1.3 Connect the machine to suitable mains power

using the mains input power lead. Switch the

mains power switch to ‘on’ to power up the

machine. Set the welding mode switch (2) to

‘MMA’.

1.4 Select the required output current using the

current control knob (9). You are now ready to

weld!

Quick Start Guide - Welder Installation

2. TIG Operation

Note:TIGoperationrequiresanargongassupply.

2.1 Connect the earth cable quick connector to the

positiveweldingpoweroutputsocket(5).Con-

nect the earth clamp to the work piece. Contact

with the work piece must be firm contact with

clean, bare metal, with no corrosion, paint or

scale at the contact point.

2.2 InsertTIGtorchpowerconnectionintothenega-

tive welding power output socket (7). Connect

TIGtorchremoteplugtoremotesocket(8)and

torchgasconnectiontotheTIGgasoutlet(6).

2.3 Connect the machine to suitable mains power

using the mains input power lead. Switch the

mains power switch to ‘on’ to power up the ma-

chine. Select ‘2T’ or ‘4T mode using the mode

selector switch (2).

2.4 Assemble the female gas quick connector to

the gas line and to the regulator outlet fitting.

Connect the gas regulator to a gas cylinder (not

included with machine) and connect the female

quick connector to the male gas inlet on the rear

of the machine. Ensure all connections are tight.

Open gas cylinder valve and adjust regulator,

flowshould bebetween 5-10l/min depending

onapplication.Re-checkregulatorflowpressure

with the torch triggered as static gas flow setting

may drop once gas is flowing.

2.5 Settheweldingcurrent(9),downslope(4)and

gas post flow (3) as required. You are now ready

to weld!

Pleasenote,theEZITIG180isaDC(DirectCurrent)outputwelder

only.ThismeansthatitisunabletoTIGweldreactivemetalssuch

asAluminiumalloysandBrass(whichrequireACoutput).DCTIG

output is suitable for steel, stainless steel and copper.

TheADVANCETIGAC/DCseriesarethemodelsdesignedforTIG

welding Aluminium and its alloys.

www.strata.co.nz

EZITIG 180

Available Parts & Accessories

EZITIG 180:

7370 Pro-Grip26TorchX12.5Ft,TgcEnd

 (LargeDinse)M12And3PinHizonePlug

AAL3550 ArcLead16mm2Cable,35-70mmPlug,4m

AEL3550 EarthLead16mm2Cable,35-70mmPlug,3m

ALS3550 MMALeadSet300A3mEarth+4mArc,

 1/2”DinseConnectors

S400EH 400AScrewTypeElect.Holder

S500EC Strata500aEarthClamp

CP3550 CablePlug-35-50mmÂ³-Male

DW3000 AutoDarkeningHelmet,Shade9-13

DW4000 AutoDarkeningHelmet,Shade9-13

 withGrindingVisor

GR101AR ArgonTwinGaugeRegulator

GR101ARFL ArgonGasRegulatorc/wFlowMeter

GR101AR-2FL ArgonRegulatorc/wTwinFlowMeter

16895 15mH/D15AExtensionLead(3x2.5mm2wiring)

TBC57Y02 LongBlackCap

TC10N23 Collet1/16(1.6mm)(2pk)

TC10N24 Collet3/32(2.4mm)(2pk)

TC10N25 Collet1/83.2mm(Pkt2)

TCB10N31 ColletBody1/16(1.6mm)(2pk)

TCB10N32 ColletBody3/32(2.4mm)(2pk)

TCB10N28 ColletBody1/8(3.2mm)(2pk)

TCC10N48 Std.CeramicCup3/8bore#6(2pk)

TCC10N47 Std.CeramicCup7/16bore#7(2pk)

TCC10N46 Std.CeramicCup1/2bore#8(2pk)

TCC10N45 Std.CeramicCup5/8bore#10(2pk)

TheseaccessorieslistedareavailablefromyourStrataSupplier.RefertotheStrataCatalogue,yourStrataSupplier

or look online at www.strata.co.nz for other accessories and consumables available.

TT16-150 ThoriatedTungstenElectrode1.6mm(3pk)

TT24-150 ThoriatedTungstenElectrode2.4mm(3pk)

TT32-150 ThoriatedTungstenElectrode3.2mm(3pk)

DCKIT DCTigComponentsStarterKit-WP17,WP18,

WP26 Suits:XTP200PRO,XMP5000

 SuitsanyTIGKitsoldwithMIGorARCwelder

TR16MS-70S-6 MildSteelTIGRod1.6mm/1kg

TR24MS-70S-6 MildSteelTIGRod2.4mm/1kg

TR32MS-70S-6 MildSteelTIGRod3.2mm/1kg

TR16SS-316 StainlessSteelTIGRod1.6mm

TR24SS-316 StainlessSteelTIGRod2.4mm

TR32SS-316 StainlessSteelTigRod3.2mm

ETCPH4825 OvercordR922.5mmElectrodes(350mm)

ETCPH4832 OvercordR923.2mmElectrodes(350mm)

ETCPH4840 OvercordR924.0mmElectrodes(350mm)

ETCPH6825 Overcord2.5mmElectrodes(350mm)

ETCPH6832 Overcord3.2mmElectrodes(350mm)

ETCPH6840 Overcord4.0mmElectrodes(350mm)

ETCPH7725 Supercito2.5mmElectrodes(350mm)

ETCPH7732 Supercito3.2mmElectrodes(450mm)

ETCPH7740 Supercito4.0mmElectrodes(450mm)

ETCPH56S25 Tenax56S2.5mmElectrodes(350mm)

ETCPH56S32 Tenax56S3.2mmElectrodes(350mm)

ETCPH56S40 Tenax56S4.0mmElectrodes(450mm)

PDL15 Plug,3Pin15A250VStraight

17844 GasInletQC

17845 3PinStrataEziTig180RemotePlug

8www.strata.co.nz

EZITIG 180

3. TCB57Y02 BackCapLong

4. TCB57Y04 BackCapShort

5. TER1MS MomentaryKit

6. UERSWL8 TriggerLead25ft

8. TERH200 LargeErgoTigHandle

9. UERKJ200 LargeKnuckleJoint

11. UERJK200 JointingRepairKit

13. UERCO200-40 Sheathx12.5ftIncLeatherCover

 UERCO200-80 Sheathx25ftIncLeatherCover

15. 46V28 PowerCablex12.5ftRubber

 46V30 PowerCablex25ftRubber

Suregrip™ Series WP26 Torch Parts

AllproductsconformtoEN60974-7andareRoHS,REACHandWEEEcompliant

3 Pin Remote Plug Connection

Gun Switch

www.strata.co.nz

EZITIG 180

Wiring Diagram

10 www.strata.co.nz

EZITIG 180

Care & Maintenance

Keep your Welding Machine

in Top Condition

TheEZITIG180doesnotrequireanyspecialmain-

tenance, however the user should take care of the

machine as follows:

• Regularlycleantheventilationslots.

• Keepthecasingclean.

• Checkallcablesbeforeuse.

• Checkelectrodeholders,worklead/clampsand

welding torches before use.

• Replacewornelectrodeholdersandearth 

clamps, which do not provide a good

connection.

• Replacewornconsumablepartsinatimely 

manner.

• Useasoftclothorbrushtocleanelectrical 

components.

• Donotuseliquidcleaningproducts,wateror

especially solvents.

• Donotusecompressedairtocleanelectrical

components as this can force dirt and dust

further into components, causing electrical short

circuits.

• Checkfordamagedparts.Donotusethewelder

with damaged parts.

• Adamagedweldermustbecarefullycheckedby

a qualified person to determine that it will operate

properly. Check for breakage of parts, mountings

and other conditions that may affect its operation.

An authorised service centre should properly

repairadamagedpart.Haveyourwelderrepaired

by an expert.

This appliance is manufactured in accordance with

relevant safety standards. Only experts must carry

out repairing of electrical appliances, otherwise

considerable danger for the user may result. Use only

genuine replacement parts. Do not use modified or

non-genuineparts.

Storing the Welder

When not in use the welder should be stored in the

dryandfrost-freeenvironment.

WARNING! Before performingcleaning/main-

tenance,replacingcables/connections,make

sure the welding machine is switched off and

disconnected from the power supply.

Electrodes

Size of Electrodes

The electrode size is determined by the thickness of

metals being joined and can also be governed by the

type of welding machine available. Small welding ma-

chines will only provide current (amperage) to run

smaller sized electrodes.

Forthinsections,itisnecessarytousesmallerelec-

trodes otherwise the arc may burn holes through the

job. A little practice will soon establish the most suit-

able electrode for a given application.

Storage of Electrodes

Always store electrodes in a dry place and in their

original containers.

Electrode Polarity

Electrodes are generally connected to the electrode

holder with the electrode holder connected positive

polarity.

The work lead is connected to the negative polarity

andisconnectedtotheworkpiece.Ifindoubtconsult

the electrode data sheet.

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EZITIG 180

High Tensile and Alloy Steels

The two most prominent effects of welding these

steels are the formation of a hardened zone in the

weld area, and, if suitable precautions are not taken,

the occurrence in this zone of under-bead cracks.

Hardenedzoneandunderbeadcracksintheweldarea

may be reduced by using the correct electrodes, pre-

heating, using higher current settings, using larger

electrodes sizes, short runs for larger electrode de-

posits or tempering in a furnace.

Manganese Steels

The effect on manganese steel of slow cooling from

high temperatures causes embrittlement. For this

reason it is absolutely essential to keep manganese

steelcool during welding by quenching after each

weld or skip welding to distribute the heat.

Cast Iron

Mosttypesofcastiron,exceptwhiteiron,areweld-

able. White iron, because of its extreme brittleness,

generally cracks when attempts are made to weld it.

Trouble may also be experienced when welding

white-heartmalleable,duetotheporositycausedby

gas held in this type of iron.

Copper and Alloys

The most important factor is the high rate of heat

conductivityofcopper,makingpre-heatingofheavy

sections necessary to give proper fusion of weld and

base metal.

Types of Electrodes

ARCWeldingelectrodesareclassifiedintoanumber

of groups depending on their applications. There are

a great number of electrodes used for specialised in-

dustrial purposes which are not of particular interest

for everyday general work. These include some low

hydrogen types for high tensile steel, cellulose types

for welding large diameter pipes, etc. The range of

electrodes dealt with in this publication will cover the

vast majority of applications likely to be encountered;

are all easy to use.

MILD STEEL :

E6011-Thiselectrodeisusedforall-positionweldingor

forweldingonrusty,dirty,less-than-newmetal.Ithasa

deep, penetrating arc and is often the first choice for repair

or maintenance work.

E6013 -Thisall-positionelectrodeisusedforwelding

clean,newsheetmetal.Itssoftarchasminimalspatter,

moderatepenetrationandaneasy-to-cleanslag.

E7014 - All positional, ease to use electrode for use on

thickersteelthanE6013.Especiallysuitableforsheetmetal

lap joints, fillet welds and general purpose plate welding.

E7018-Alow-hydrogen,all-positionelectrodeusedwhen

qualityisanissueorforhard-to-weldmetals.Ithastheca-

pability of producing more uniform weld metal, which has

better impact properties at low temperatures.

CAST IRON:

ENI-CL -Suitableforjoiningallcastironsexceptwhite

cast iron.

STAINLESS STEEL:

E318L-16 -Highcorrosionresistances.Idealfordairy

work etc.

Electrodes for joining different metals

Effects of MMA Welding Various Materials

12 www.strata.co.nz

EZITIG 180

Flat Position,

Down Hand Butt Weld

(Fig 1-11)

Flat Position,

Gravity Fillet Weld

(Fig 1-12)

Horizontal Position,

Butt Weld

(Fig 1-13)

Horizontal-Vertical

(HV) Position

(Fig 1-14)

Vertical Position,

Butt Weld

(Fig 1-15)

Vertical Position,

Fillet Weld

(Fig 1-16)

Overhead Position,

Butt Weld

(Fig 1-17)

Overhead Position,

Fillet Weld

(Fig 1-18)

Joint Preparations

Inmanycases,itwillbepossibletoweldsteelsec-

tions without any special preparation. For heavier

sections and for repair work on castings, etc., it will

be necessary to cut or grind an angle between the

pieces being joined to ensure proper penetration of

the weld metal and to produce sound joints.

In general, surfaces being welded should be clean

and free of rust, scale, dirt, grease, etc. Slag should

beremovedfromoxy-cutsurfaces.Typicaljointde-

signsareshowninFigure1-19.

Open Square Butt Joint (Fig

1-19a)

Gapvariesfrom1.6mm(1/16”)

to4.8mm(3/16”)dependingonplatethickness

Single Vee Butt Joint

(Fig 1-19b)

Notlessthan45°

Single Vee Butt Joint (Fig

1-19c)

Notlessthan70°

1.6mm(1/16”)max.

1.6mm(1/16”)

Double Vee Butt Joint (Fig

1-19d)

Notlessthan70° 1.6mm(1/16”)max.

1.6mm(1/16”)

Basic MMA Welding Guide

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EZITIG 180

Lap Joint (Fig 1-19e)

Fillet Joint (Fig 1-19f)

Corner Weld

(Fig 1-19g)

Tee Joints

(Fig 1-19h)

Edge Joint

(Fig 1-19i)

Plug Welds

(Fig 1-19j)

MMA Welding Techniques

A Word for Beginners

For those who have not yet done any welding, the

simplest way to commence is to run beads on a piece

ofscrapplate.Usemildsteelplateabout6.0mmthick

and a 3.2mm electrode.

Clean any paint, loose scale or grease off the plate

and set it firmly on the work bench so that welding

canbecarriedoutinthedownhandposition.Make

surethattheWorkLead/Clampismakinggoodelec-

trical contact with the work, either directly or through

theworktable.Forlightgaugematerial,alwaysclamp

the work lead directly to the job, otherwise a poor cir-

cuit will probably result.

The Welder

Place yourself in a comfortable position before begin-

ning to weld. Get a seat of suitable height and do as

much work as possible sitting down. Don’t hold your

body tense. A taut attitude of mind and a tensed body

willsoonmakeyoufeeltired.Relaxandyouwillfind

that the job becomes much easier. You can add much

to your peace of mind by wearing a leather apron and

gauntlets. You won’t be worrying then about being

burnt or sparks setting alight to your clothes.

Place the work so that the direction of welding is

across, rather than to or from, your body. The elec-

trode holder lead should be clear of any obstruction

so that you can move your arm freely along as the

electrodeburnsdown.Iftheleadisslungoveryour

shoulder, it allows greater freedom of movement and

takes a lot of weight off your hand. Be sure the insula-

tion on your cable and electrode holder is not faulty;

otherwise you are risking an electric shock.

Striking the Arc

Practice this on a piece of scrap plate before going on

to more exacting work. You may at first experience

difficultyduetothetipoftheelectrode“sticking”to

the work piece. This is caused by making too heavy

a contact with the work and failing to withdraw the

electrode quickly enough. A low amperage will accen-

tuateit.Thisfreezing-onofthetipmaybeovercome

14 www.strata.co.nz

EZITIG 180

20o

1.6mm(1/16”)

Striking an Arc

(Fig 1-20)

Arc Length

The securing of an arc length necessary to produce a

neat weld soon becomes almost automatic. You will

find that a long arc produces more heat.

A very long arc produces a crackling or spluttering

noise and the weld metal comes across in large, ir-

regular blobs. The weld bead is flattened and spatter

increases. A short arc is essential if a high quality

weld is to be obtained although if it is too short there

is the danger of it being blanketed by slag and the

electrodetipbeingsolidifiedin.Ifthisshouldhappen,

give the electrode a quick twist back over the weld to

detachit.Contactor“touch-weld”electrodessuchas

E7014Stickelectrodesdonotstickinthisway,and

make welding much easier.

Rate of Travel

After the arc is struck, your next concern is to main-

tain it, and this requires moving the electrode tip to-

wards the molten pool at the same rate as it is melting

away. At the same time, the electrode has to move

along the plate to form a bead.

Making Welded Joints

Havingattainedsomeskillinthehandlingofanelec-

trode, you will be ready to go on to make up welded

joints.

A. Butt Welds

Set up two plates with their edges parallel, as shown

in Figure 1-21, allowing 1.6mm to 2.4mm gap be-

tween them and tack weld at both ends. This is to

prevent contraction stresses from the cooling weld

metal pulling the plates out of alignment.

Platesthickerthan6.0mmshouldhavetheirmating

edgesbevelledtoforma70ºto90ºincludedangle.

This allows full penetration of the weld metal to the

root. Using a 3.2mm E7014 Stick electrode at 100

amps, deposit a run of weld metal on the bottom of

the joint.

Do not weave the electrode, but maintain a steady

rate of travel along the joint sufficient to produce a

well-formedbead.Atfirstyoumaynoticeatendency

for undercut to form, but keeping the arc length short,

theangleoftheelectrodeatabout20ºfromvertical,

and the rate of travel not too fast, will help eliminate

this.

Tack Weld

Butt Weld

(Fig 1-21)

Electrode

20o-30o

Tack Weld

by scratching the electrode along the plate surface

in the same way as a match is struck. As soon as

the arc is established, maintain a 1.6mm to 3.2mm

gap between the burning electrode end and the par-

ent metal. Draw the electrode slowly along as it melts

down.

Another difficulty you may meet is the tendency, af-

ter the arc is struck, to withdraw the electrode so far

that the arc is broken again. A little practice will soon

remedy both of these faults.

Theelectrodeisdirectedattheweldpoolatabout20º

from the vertical. The rate of travel has to be adjusted

sothatawell-formedbeadisproduced.

Ifthetravelistoofast,thebeadwillbenarrowand

strung out and may even be broken up into individual

globules.Ifthetravelistooslow,theweldmetalpiles

up and the bead will be too large.

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EZITIG 180

Weld Build Up Sequence

(Fig 1-22)

Heavyplatewillrequireseveralrunstocompletethe

joint. After completing the first run, chip the slag out

andcleantheweldwithawirebrush.Itisimportant

to do this to prevent slag being trapped by the second

run. Subsequent runs are then deposited using either

a weave technique or single beads laid down

inthesequenceshowninFigure1-22.Thewidthof

weave should not be more than three times the core

wire diameter of the electrode.

When the joint is completely filled, the back is either

machined, ground or gouged out to remove slag

which may be trapped in the root, and to prepare a

suitablejointfordepositingthebackingrun.Ifaback-

ing bar is used, it is not usually necessary to remove

this, since it serves a similar purpose to the backing

run in securing proper fusion at the root of the weld.

B. Fillet Welds

These are welds of approximately triangular cross-

section made by depositing metal in the corner of two

facesmeetingatrightangles.RefertoFigure1-14,

1-23and1-24.

A piece of angle iron is a suitable specimen with which

to begin, or two lengths of strip steel may be tacked

togetheratrightangles.Usinga3.2mmE7014Stick

electrodeat100amps,positionangleironwithone

leg horizontal and the other vertical. This is known as

ahorizontal-vertical(HV)fillet.

Strike the arc and immediately bring the electrode to

a position perpendicular to the line of the fillet and

about45ºfromthevertical.Someelectrodesrequire

beingslopedabout20ºawayfromtheperpendicular

position to prevent slag from running ahead of the

weld.RefertoFigure1-23.

Do not attempt to build up much larger than 6.4mm

width with a 3.2mm electrode, otherwise the weld

metal tends to sag towards the base, and undercut

formsontheverticalleg.Multi-runscanbemadeas

showninFigure1-24.WeavinginHVfilletweldsis

undesirable.

Electrode Position for HV

Fillet Weld (Fig 1-23)

The electrode needs to be moved along fast enough

to prevent the slag pool from getting ahead of the arc.

To complete the joint in thin plate, turn the job over,

clean the slag out of the back and deposit a similar

weld.

C. Vertical Welds

1. Vertical Up

Tack weld a three feet length of angle iron to your

work bench in an upright position. Use a 3.2mm

E7014 Stick electrode and set the current at 100

amps.Makeyourselfcomfortableonaseatinfrontof

the job and strike the arc in the corner of the fillet. The

electrodeneedstobeabout10ºfromthehorizontalto

enableagoodbeadtobedeposited.ReferFig.1-25.

Multi-Runs in HV Fillet Weld

(Fig 1-24)

Single Run Vertical Fillet Weld

(Fig 1-25)

16 www.strata.co.nz

EZITIG 180

Weaving motion for

second and subsequent

runs

Pause at edge

of weave

Multi Run Vertical Fillet Weld (Fig

1-26)

Examples of Vertical Fillet Welds

(Fig 1-27)

Pause at edge of weave

allows weld metal to build

up and eliminates undercut

Note: Weld contour

when insufficient pause

at edge of weave

CORRECT INCORRECT

2. Vertical Down

TheE7014Stickelectrodemakesweldinginthisposi-

tionparticularlyeasy.Usea3.2mmelectrodeat100

amps. The tip of the electrode is held in light contact

with the work and the speed of downward travel is

regulated so that the tip of the electrode just keeps

ahead of the slag. The electrode should point up-

wardsatanangleofabout45º.

Theelectrodeisheldat45ºtothehorizontalandtilted

10ºinthelineoftravel(Figure1-28).Thetipofthe

electrode may be touched lightly on the metal, which

helps to give a steady run. A weave technique is not

advisable for overhead fillet welds.

Usea3.2mmE6013Stickelectrodeat100amps,and

deposit the first run by simply drawing the electrode

along at a steady rate. You will notice that the weld

deposit is rather convex, due to the effect of gravity

before the metal freezes.

Tilted10o in

line of travel

Overhead Fillet Weld

(Fig 1-28)

Angle tacked to pipe

45o to plate

Use a short arc, and do not attempt to weave on the

firstrun.Whenthefirstrunhasbeencompletedde-

slag the weld deposit and begin the second run at the

bottom. This time a slight weaving motion is neces-

sary to cover the first run and obtain good fusion at

the edges.

At the completion of each side motion, pause for a

moment to allow weld metal to build up at the edges,

otherwise undercut will form and too much metal

willaccumulateinthecentreoftheweld.Figure1-26

illustratesmulti-runtechniqueandFigure1-27shows

the effects of pausing at the edge of weave and of

weaving too rapidly.

3. Overhead Welds

Apart from the rather awkward position necessary,

overhead welding is not much more difficult that

down hand welding.

Set up a specimen for overhead welding by first tack-

ing a length of angle iron at right angles to another

piece of angle iron or a length of waste pipe. Then

tack this to the work bench or hold in a vice so that

the specimen is positioned in the overhead position

as shown in the sketch.

Other Knowledge

& Resources

Please refer to Euroquip website

www.euroquip.co.nz/ Downloads.html

for knowledgebase articles & operation videos.

www.strata.co.nz

EZITIG 180

MMA Troubleshooting

18 www.strata.co.nz

EZITIG 180

Tig Welding Techniques

Tig Welding Fusion Technique

ManualTIGweldingisoftenconsideredthemostdif-

ficult of all the welding processes. Because the welder

must maintain a short arc length, great care and skill

are required to prevent contact between the electrode

and the work piece. Similar to Oxygen Acetylene torch

welding, TIG welding normally requires two hands

and in most instances requires the welder to manu-

ally feed a filler wire into the weld pool with one hand

while manipulating the welding torch in the other.

However,someweldscombiningthinmaterialscan

be accomplished without filler metal like edge, cor-

ner, and butt joints.

ThisisknownasFusionweldingwheretheedgesof

the metal pieces are melted together using only the

heatandarcforcegeneratedbytheTIGarc.Oncethe

arc is started the torch tungsten is held in place until a

weld pool is created, a circular movement of the tung-

sten will assist is creating a weld pool of the desired

size. Once the weld pool is established tilt the torch

atabouta75°angleandmovesmoothlyandevenly

along the joint while fusing the materials together.

of the molten pool, the arc will melt the filler wire into

the weld pool as the torch is moved forward. Also a

dabbing technique can be used to control the amount

of filler wire added, the wire is fed into the molten

pool and retracted in a repeating sequence as the

torchismovedslowlyandevenlyforward.Itisim-

portant during the welding to keep the molten end of

the filler wire inside the gas shield as this protects the

end of the wire from being oxidised and contaminat-

ing the weld pool.

TIG Welding Guide

Tig Welding with Filler Wire Technique

InmanysituationswithTIGwelding,itisnecessary

to add a filler wire into the weld pool to build up weld

reinforcement and create a strong weld. Once the arc

is started the torch tungsten is held in place until a

weld pool is created, a circular movement of the tung-

sten will assist is creating a weld pool of the desired

size. Once the weld pool is established tilt the torch

atabouta75°angleandmovesmoothlyandevenly

along the joint. The filler metal is introduced to the

leading edge of the weld pool. The filler wire is usually

heldatabouta15°angleandfedintotheleadingedge

Travel Direction

75o

Formaweldpool Angle torch Movethetorchslowly

and evenly forward

75o

Travel Direction

Formaweldpool Angle torch AddTIGfillerwire

Retractthefillerwire Movethetorchforwardto

the front of the weld pool

Repeattheprocess

15o

Gas Shield

Electrodes

Tungsten Electrodes

Tungsten is a rare metallic element used for manufac-

turingTIGweldingelectrodes.TheTIGprocessrelies

on tungsten’s hardness and high temperature resist-

ance to carry the welding current to the arc. Tungsten

hasthehighest meltingpointofanymetalat3410

degrees Celsius.

Tungstenelectrodesarenon-consumableandcome

in a variety of sizes, they are made from pure tung-

sten or an alloy of tungsten and other rare earth ele-

ments. Choosing the correct tungsten depends on the

material being welded, the amount of amps required

and whether you are using AC or DC welding current.

Tungstenelectrodesarecolour-codedattheendfor

easy identification.

Thoriated Tungsten Electrodes

Thoriated tungsten electrodes (AWS classification

EWTh-2)containaminimumof97.30percenttung-

stenand1.70to2.20percentthoriumandarecalled2

percent thoriated. They are the most commonly used

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EZITIG 180

electrodes today and are preferred for their longevity

and ease of use.

Thorium increases the electron emission qualities of

the electrode, which improves arc starts and allows

forahighercurrent-carryingcapacity.Thiselectrode

operates far below its melting temperature, which

results in a considerably lower rate of consumption

and eliminates arc wandering. Compared with other

electrodes, thoriated electrodes deposit less tungsten

into the weld puddle, so they cause less weld con-

tamination.

Thoriumisalow-levelradioactivehazardandmany

users have switched to other alternatives. Thorium

is an alpha emitter but when enclosed in a tungsten

matrix, the risks are negligible. Thus holding a stick

of Thoriated tungsten in your hand should not pose

a great threat unless a welder has open cuts on their

skin. Thoriated tungsten should not get in contact

with open cuts or wounds. The more significant dan-

ger to welders can occur when thorium oxide gets

into the lungs. This can happen from the exposure to

vapoursduringweldingorfromingestionofmaterial/

dustinthegrindingofthetungsten.Followthemanu-

facturer’s warnings, instructions, and the Safety Data

Sheet (SDS) for its use.

jagged edges, imperfections, or poor surface finishes

not visible to the eye that will contribute to weld in-

consistency and weld defects.

Always grind the tungsten in a longitudinal direc-

tion. Tungsten electrodes are manufactured with the

molecular structure of the grain running lengthwise

and thus grinding crosswise is “grinding against the

grain.”Ifelectrodesaregroundcrosswise,theelec-

trons have to jump across the grinding marks and

the arc can start before the tip and wander. Grinding

longitudinally with the grain, the electrons flow stead-

ily and easily to the end of the tungsten tip. The arc

starts straight and remains narrow, concentrated, and

stable.

Tungsten Electrode Current Ranges

1.0mm 15-80

1.6mm 70-150

2.4mm 150-250

3.2mm 250-400

4.0mm 400-500

Tungsten DC Current Amps Torch

Diameter Negative 2% Thoriated

Tungsten Preparation

Always use DIAMOND wheels when grinding and

cutting. While tungsten is a very hard material, the

surface of a diamond wheel is harder, and this makes

for smooth grinding. Grinding without diamond

wheels, such as aluminium oxide wheels, can lead to

Grind longitudinal on the

grinding wheel DO NOT grind across the

grinding wheel

Electrode Tip/Flat

The shape of the tungsten electrode tip is an impor-

tant process variable in precision arc welding. A good

selectionoftip/flatsizewillbalancetheneedforsev-

eral advantages. The bigger the flat, the more likely

arc wander will occur and the more difficult it will be

toarcstart.Increasingtheflattothemaximumlevel

that still allows arc start and eliminates arc wonder

will improve the weld penetration and increase the

electrode life. Some welders grind electrodes to a

sharp point, which makes arc starting easier but can

contribute to decreased welding performance due to

the tip me lting and falling into the weld pool.

2.5xTungstenDiameter

Flat

Tip

Pointed

Tip

Electrode Included Angle/Taper

DC Welding Tungsten electrodes for DC welding

should be ground longitudinally and concentrically

with diamond wheels to a specific included angle in

conjunctionwiththetip/flatpreparation.Differentan-

gles produce different arc shapes and offer different

weld penetration capabilities.

20 www.strata.co.nz

EZITIG 180

In general, electrodes that have an appropriate in-

cluded angle and a suitable flat on the tip, exhibit the

following benefits:

• Lastlonger

• Havebetterweldpenetration

• Haveanarrowerarcshape

• Canhandlemoreamperagewithouteroding.

Sharper electrodes with smaller included angle provide:

• Offerlessarcweld

• Haveawiderarc

• Haveamoreconsistentarc

The included angle determines weld bead shape and

size. Generally, as the included angle increases, pen-

etration increases and bead width decreases.

Included

Angle

FlatSpot

Diameter

Tungsten Electrode Preparation

Tungsten

Electrode

Diameter

(mm)

Flat Spot

Diameter

at the Tip

(mm)

Tip

Included

Angle

(Degrees)

Current

Range

(Amps)

Current

Pulsed

(Amps)

1.6 .500 25 08-50 05-10

  .800 30 10-70 10-140

2.4 .800 35 12-90 12-180

  1.100 45 15-150 15-250

3.2 1.100 60 20-200 20-300

  1.500 90 25-250 25-350

TIG Troubleshooting

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Strata EZITIG 180 Operating Instructions Manual

Brand: Strata

Model: EZITIG 180

Category: Welding System

Type: Operating Instructions Manual

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Strata EZITIG 180 Operating Instructions Manual

Strata EZITIG 180 Operating Instructions Manual

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